Needle removal and disposal apparatus

ABSTRACT

A geared slot needle remover for engaging and rotatably removing a needle from a holder, comprises a support member having an elongated slot for receiving a disposable hypodermic needle, a plurality of gear teeth along one side of the slot for engaging splines on a needle hub for rotating the needle hub and unthreading it from a holder when the gear teeth and the axis of the needle hub are moved transverse to one another, and an elongated lip overlying a substantial length of the slot for engaging and holding the needle hub against removal from the slot. In an alternate embodiment the gear slot is formed in a flexible arm having an inner end secured to the support member, and a needle hub guide for guiding the needle hub along the gear teeth upon movement of the needle holder along the axis of the needle.

REFERENCE TO RELATED APPLICATION

The present application is a continuation-in-part of application Ser.No. 07/946,523, filed Sep. 16, 1992, now U.S. Pat. No. 5,402,887,entitled "NEEDLE EXTRACTOR FOR DISPOSABLE CONTAINERS".

BACKGROUND OF THE INVENTION

The present invention relates to needle removal devices for syringes,and pertains particularly to an improved needle removal device for quickand easy removal of needles from syringes.

The safe and efficient removal of sharps such as hypodermic needles andthe like is a tremendous problem for medical and other healthcarefacilities. Needles and syringes are often separated for disposal andsometimes for re-use of the syringe. This is particularly true for bloodcollection-type syringes which use a vacuum tube for drawing the blood.It is critical that medical personnel have means for removal anddisposal of needles without risk of puncture of the skin.

Disposable containers have been developed in recent years which providea reasonably high degree of security for disposable sharps articles andmaterials from hospitals and clinics. Many of these articles, such asneedles and surgical blades known as sharps, and other similar articlesand materials, must be disposed of in a manner to keep them out of thehands of unauthorized persons and to keep them from being reused. Thesecontainers are designed to prevent the removal of materials from thecontainer under ordinary circumstances. It is desirable in mostinstances that the container provide means to remove the needle fromsyringes and other such instruments prior to disposal or for separatedisposal.

One secure container of the aforementioned type is that disclosed inprior U.S. Pat. No. 4,502,606, issued Mar. 5, 1985, and directed to alocking closure for disposable containers. These containers, haveusually been provided with needle removal tools in the form of one ormore slots which act as a wrench for removal of the needles fromsyringes and the like. These needle removal tools are not onlyconvenient, but also provide a safe means for removal of the needle. Thesafe removal of the needle is essential to protect hospital personnelfrom certain injury and from contagious diseases.

Many prior disposable containers have had needle removal tools builtinto the top thereof adjacent the disposal opening. This is a convenientand desirable arrangement. However, the prior tools, while normallysuitable for most applications, require rotation of the syringe barrelfor removal of the needle. This is often inconvenient for the user,particularly if the container must be hand held. An example of animproved needle removal slot is disclosed in my U.S. Pat. No. 4,984,686,granted Jun. 15, 1991.

In the above identified parent application, a needle removal slot isprovided which has gear teeth for engaging the splines or flutes of aneedle hub for rotatably unthreading the needle. However, furtherimprovements are desirable.

It is, therefore, desirable that an improved, convenient, safe andeffective needle removal device be available.

SUMMARY OF THE INVENTION

It is the primary object of the present invention to provide an improvedneedle removal means for disposable containers.

In accordance with the primary aspect of the present invention, a needleremoval device for a disposable container comprises an elongated slot,with a section of gear teeth along one side for engagement with splineson the hub of a needle to rotate and unscrew the needle from its holderas it is passed along the slot transverse to the needle axis. Oneembodiment includes a flap that engages the needle hub to retain it inthe slot. Another embodiment provides the geared slot in a flexible armthat moves transverse to an axially moved needle to unscrew it.

BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS

The above and other objects and advantages of the present invention willbecome apparent from the following description when read in conjunctionwith the accompanying drawings wherein:

FIG. 1 is a top plan view of a closure assembly incorporating apreferred embodiment of the invention;

FIG. 2 is a top plan partial view like FIG. 1, showing an alternateembodiment;

FIG. 3 is a sectional view taken on line 3--3 of FIG. 1;

FIG. 4 is a sectional view taken on line 4--4 of FIG. 2;

FIG. 5 is a sectional view taken on line 5--5 of FIG. 2;

FIG. 6 is a sectional view taken on line 6--6 of FIG. 2;

FIG. 7 is a side elevation view in section of a further embodiment ofthe insertion; and

FIG. 8 is a bottom plan view looking upward from below the embodiment ofFIG. 7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and to particularly FIG. 1, there isillustrated a container closure assembly, designated generally by thenumeral 10, which includes a needle removal device 12 constructed inaccordance with an exemplary embodiment of the invention. This closureassembly comprises a top support or frame member 12, which in theillustrated embodiment has generally rectangular configuration formounting on and covering the upwardly opening mouth or open top of acontainer (not shown). This top is permanently attached to a plastictype disposable container of the type typically used for the disposal ofsyringes, sharps and the like. These type containers are disclosed in anumber of my previous patents, as will be mentioned.

The needle removal slot 12 is shown formed in a closure frame 14, whichin the illustrated embodiment has a generally rectangular configuration,with an opening 16 for syringes, and covers 18 and 20 for the openingand the needle slot. The needle removal device may also be incorporatedinto any number of other container closure assemblies associated withvarious container closures, such as disclosed for example in my U.S.Pat. No. 4,984,686. These tops may be permanently attached to a plastictype disposable container of the type typically used for disposal ofsharps, and other objects and the like, such as disclosed in a number ofmy previous patents.

The illustrated closure assembly is designed for use in conjunction withcontainers for the disposal of vacuum type syringes widely used fordrawing of blood samples. The closure comprises a rectangular panel 14,with an opening 16 for receiving spent syringes. Adjacent to the opening16 is a removal device in accordance with the invention, designatedgenerally by the numeral 12, for the removal of needles from the syringebody.

The opening 16 and the needle removal slot 12 are positioned within arectangular recessed portion, as illustrated, with hinged cover members18 and 20 hinged to one side of the top frame. The hinge covers 18 and20 are shown pivoted to an open position, and each include locking tabs22 and 24 for engaging slots 26 and 28 for latching in a permanentlylatched or closed position when the container is filled and ready fordisposal.

Referring now specifically to the needle removal slot, it will be notedthat the slot comprises a first or needle receiving portion 26, a secondor intermediate and hub receiving portion 28, and an end or needle dropsection 30. The overall slot is recessed downward into the closure frameassembly, as will be appreciated from FIGS. 2 and 3. The slot also opensdirectly into a container for direct disposal of needles.

The needle inlet slot portion 26 slopes downward from the upper surfaceof frame 14, with opposing parallel side walls 32 and 34 to theintermediate section 28. The intermediate section 28 extends generallyhorizontally and is formed of a notched wall formed with teeth 36, 38and 40 and a straight opposing wall 42. The opposing straight wall 42biases against the hub radial flange and biases the flutes of the hubinto engagement with the teeth 36, 38 and 40, causing rotation of thehub and needle as a syringe is held against rotation and passed or movedalong the slot transvers to the axis of the needle.

A terminal end of the slot 44 is formed of a continuation of side wall42, which continues from an upper surface and an opposing side wallabove the teeth 36, 38 and 40 and the slot 32. The terminal end portionof the slot extends beneath a generally C or crescent shaped hook orinwardly extending rim 44, which extends over and hooks the radiallyextending flange of a needle hub for exerting force to force it from theend of a barrel. The teeth 36, 38 and 40 step down slightly from the topsurface to the hook 44, permitting a hub flange to extend beneath thehook 44. This also accommodates the unscrewing motion of the hub as itmoves downward out of the end of a barrel.

The overall slot 12 is recessed below an upper surface of a supportstructure, such as a container top, so that there is provided support orspacer surfaces which engage the end of a syringe barrel, and space orposition the hub flutes to engage the intermediate portion of the slotand teeth 36, 38, and 40. This is more fully illustrated in the parentapplication which has been allowed and is incorporated herein inreference as though fully set forth. In particular, as illustrated inthe parent application, a syringe barrel shown in phantom has a neckinto which a needle hub is threaded. The end surface of the barrelengages the surfaces surrounding or to each side of the slot, andpermits the needle hub to extend down just sufficient to engage to gearteeth 36, 38 and 40. In the instant application the barrel end 52a willengage surface 14a surrounding the slot.

As the hub unthreads from the end of the barrel, it moves downward aspermitted by the downward stepped upper surfaces of the teeth 36, 38 and40 (e.g. FIG. 3). At the end of the stroke, the flange of the hubextends beneath the horseshoe grip or hook 44 to give an axial force onthe needle and hub assembly if needed.

Referring to FIG. 2 of the drawings, a modification of the basic gearedslot of FIG. 1 includes overlying lips or flaps 46 and 48 at the inletend of the slot 50 and extending along the side of the slot opposite ofthe gear teeth. These flaps serve as retainers to latch behind the uppersurface of the needle hub and retain it in place to prevent it frombeing pulled out of the slot once inserted. This will be bestappreciated in viewing FIG. 4 wherein a conventional needle hub isillustrated, and in FIG. 5 and 6 wherein it can be seen that the flapswill engage behind or above the hub flange and retain it in place. Insome instances it may be necessary to campfer the end of the holder neckto provide a space behind the hub rim or flange.

As specifically illustrated in FIG. 4, a conventional tubular holder orbarrel 52 for the vacuum type containers includes a neck 54 having aninternally threaded socket for receiving a needle assembly having aforward extending elongated needle 56 and an inwardly extending needle58 which is covered by a sheath valve and punctures the vacuum tube. Ahub assembly includes an upper threaded portion 60, intermediate disklike flange 62 and forwardly extending flutes or splines 64. Thethreaded portion 60 threading into the internally threaded socket (notshown) in neck 54. The flutes are normally four in number but can serveor act roughly as a pinion gear, which cooperates with the teeth in theslot in a manner similar to a rack gear or linear gear. Thus, thesplines on the hub and the gear teeth in the slot act as a rack andpinion gear combination.

In operation, a syringe barrel 62 is grasped in the hand, and the needle56 is inserted in the inlet to slot 28 and permitted to slide downward,engaging flute 64 in the tooth section of the slot as the barrel isgrasped and held against rotation and forced forward along the slot. Asthe barrel is moved forward along the slot, the flutes 64 engaging theteeth 36, 38 and 40 force the hub to rotate counter clockwise relativeto the end of the syringe barrel, forcing the needle hub to unthread orunscrew from the neck 54 of the syringe barrel.

As the needle and hub assembly moves to the terminal end of the slot,the needle and hub assembly is permitted to fall from the end of thebarrel. In case it is frictionally held in position, the semicirculargrip 46 may be engaged by the hub flange as the barrel is pulled upward,forcing the threaded portion of the needle hub from the end of thebarrel neck 54. Thus, the needle is quickly, safely and effectivelyremoved from the end of the syringe barrel.

In the FIGS. 2 through 6 embodiment the syringe barrel is forceddownward until the lips or flaps 46 and 48 engage the upper surface ofthe flange 62 which retains it in place. As the barrel of the syringe ismoved forward, lip or flap 52 engages the hub flange 62 as the flutes orsplines of the hub engage the tooth 32 and retains it in place as thehub moves forward along the slot. At the end of the slot the flange ofthe hub extends beneath the hook or rim 44 so that as the barrel 52 ispulled upward the needle hub is engaged and forced out of the end of thebarrel.

Referring now to FIGS. 7 and 8 an alternate embodiment of the inventionis illustrated. The device or apparatus of FIGS. 7 and 8 comprises agenerally stationary support member 66 which may be a wall or otherportion such as a closure assembly of a disposable container. Thesupport member 66 includes an aperture or throughbore 68 which ispreferably formed as a tubular sleeve by walls 70 extending normal tothe surface of the support member such as into the container. Anelongated removal slot assembly is associated with the opening 68 andcomprises an elongated flexible arm having an inner end portion 72 forattachment to the surface of the support member 66 and outer flexiblearm portion 74 with an intermediate portion 76. The intermediate portionextends at 90° from the base or attachment portion 76 with the flexibleend portion 74 at the outer end thereof and including a geared needleremoval slot 78. The geared slot 78 includes a plurality of geared teeth80, 82 and 84 extending along one side thereof and an overlying oropposing lip 86 on the opposite side thereof. A terminal end of the slotincludes an overlying hook or rim portion 88 as in the previousembodiment.

The arm assembly may be attached to the support member in any suitablemanner such as that illustrated which includes an overlying strap 90spaced from the undersurface of the wall 66 and forming a slot 92through which the arm 72 extends and a slot 94 extending and latchinginto a slot 96 near the end of the strap or arm 72. Thus, the overallslot assembly can be easily mounted by simply slipping the end thereofthrough the slot 92 and 94 latching into place. The inlet end of theslot is aligned with the axis of the bore 68 to properly position theneedle hub at the beginning of the slot.

In operation, as a syringe or needle holder barrel 98 having a needleassembly including a splined hub 100 threadably engaging a socket in aneck 102 is inserted into apparatus or sleeve 68 the splines of the hub100 extend into the slot as shown in FIG. 8 forward of the series ofgeared teeth 80 through 84. As the barrel is forced downward along itsaxis and the arm portion 74 is forced to flex downward and moves to oneside pulling the slot portion across the axis of the needle. This movesthe gear teeth across the hub and in mesh with the splines forcing thehub to rotate counter-clockwise as it moves downward to the end of theslot 78. This unthreads the needle from its socket whereby it is forcedout of the socket and drops into the container or other disposablecontainer. The flexible arm then moves back to the ready position whenthe holder barrel is removed from the bore.

While the needle slot is illustrated in the present example inconjunction with a specific disposable container top, it is to beunderstood that it may be utilized in conjunction with substantially anycontainer top, such as disclosed in any number of my prior patents. Itmay also be used in conjunction with other needle slots, such as shownfor example in my U.S. Pat. No. 4,984,684 and others.

While I have illustrated and described my invention by means of specificembodiments, it is to be understood that numerous changes andmodifications may be made therein without departing from the spirit andscope of the invention as defined in the appended claims.

We claim:
 1. A geared needle remover for engaging and rotatably removinga needle from a holder, comprising:a stationary support member having anopening for receiving a disposable hypodermic needle; an elongated slotassociated with said opening and having a plurality of gear teeth alongone side thereof for engaging splines on a needle hub for rotating theneedle hub and unthreading it from a holder when the gear teeth and theaxis of the needle are moved transverse to one another; and an elongatedlip overlying a substantial length of said slot for engaging and holdingthe needle hub against removal from the slot.
 2. A geared needle removeraccording to claim 1 wherein said support member includes guide meanscomprising a generally cylindrical socket for reciprocally receiving aneedle receiving end of a needle holder.
 3. A geared needle removeraccording to claim 2 wherein said slot comprises a flexible arm havingan inner end secured to said support member, and an outer end includingsaid gear teeth and needle hub guide means for guiding the needle hubalong said gear teeth upon movement of the needle holder along the axisof the needle.
 4. A geared needle remover according to claim 1 whereinsaid slot comprises a flexible arm having an inner end secured to saidsupport member, and an outer end including said gear teeth and needlehub guide means for guiding the needle hub along said gear teeth uponmovement of the needle holder along the axis of the needle.
 5. A gearedneedle remover according to claim 1 wherein said slot comprises aflexible arm having an inner end secured to said support member, and anouter end including said in-line gear teeth and needle hub guide meansfor guiding the needle hub along upon movement of the needle holderalong the axis of the needle.
 6. A geared needle remover according toclaim 1 wherein:said support member is a closure frame for a disposablecontainer; and said guide means comprises a generally cylindrical sleevefor reciprocally receiving a needle receiving end of a needle holder. 7.A geared needle remover according to claim 6 wherein said slot comprisesa arm assembly having an inner substantially straight end secured to anunder surface of said closure frame, and an outer curved end includingsaid gear teeth.
 8. A geared needle remover according to claim 7 whereinsaid sleeve has a central axis, one end of said slot is aligned withsaid axis slot comprises a arm assembly having an inner substantiallystraight end secured to an under surface of said closure frame, and anouter curved end including said gear teeth.
 9. A geared needle removeraccording to claim 7 wherein said sleeve has a central axis, and saidouter curved end curves across said axis with one end of said slotaligned with said axis.
 10. A geared needle remover for engaging androtatably removing a needle from a holder, comprising:a closure framefor a disposable container; a generally cylindrical opening in saidclosure frame for receiving a holder for a disposable hypodermic needle;an elongated slot spaced from and aligned with said opening, said slothaving a plurality of gear teeth along one side thereof for engagingsplines on a needle hub for rotating the needle hub and unthreading itfrom a holder when the gear teeth and the axis of the needle are movedtransverse to one another.
 11. A geared needle remover according toclaim 10 wherein said elongated slot includes needle hub guide means forguiding the needle hub along said gear teeth upon movement of the needleholder along the axis of the needle.
 12. A geared needle removeraccording to claim 10 wherein said slot comprises a flexible arm havingan inner end secured to said support member, and an outer end includingsaid in-line gear teeth and needle hub guide means for guiding theneedle hub along upon movement of the needle holder along the axis ofthe needle.
 13. A geared needle remover according to claim 10 whereinsaid opening comprises a generally cylindrical sleeve for reciprocallyreceiving a needle receiving a needle holder.
 14. A geared needleremover according to claim 10 wherein said slot comprises an armassembly having an inner substantially straight end secured to an undersurface of said closure frame, and an outer curved end including saidgear teeth.
 15. A geared needle remover according to claim 14 whereinsaid sleeve has a central axis, one end of said slot is aligned withsaid axis slot comprises a arm assembly having an inner substantiallystraight end secured to an under surface of said closure frame, and anouter curved end including said gear teeth.
 16. A geared needle removeraccording to claim 15 wherein said sleeve has a central axis, and saidouter curved end curves across said axis with one end of said slotaligned with said axis.
 17. A geared needle remover according to claim10 wherein said slot includes a retaining flap for overlying andretaining a needle hub in said slot.